Vibrating pallet system for automated wire insertion

ABSTRACT

A method and an apparatus relate to the insertion of one or more wires into a cavity of a fixture of a structure or component. The wire insertion apparatus includes a grommet, a gripper adapted to interface with the grommet, and at least a first vibrating element. The first vibrating element is connected to and vibrates one or more of the apparatus, the grommet, the gripper, the wire, and/or a component of the apparatus. Vibration, induced in any direction, enables the cavities to shift position during insertion relative to the contact, thus increasing the tolerance of the cavity, reducing the failure rate of wire insertion, and reducing total production time. The vibration breaks the static friction of the contact in the grommet or dielectric opening, creates the positive locating required to insert the contact in the grommet and/or dielectric, and/or pivots the contact.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure is a divisional of U.S. application Ser. No.15/010,525, filed Jan. 29, 2016. The entire content of the foregoingapplication is incorporated by reference into the present disclosure.

BACKGROUND Field

The present disclosure generally relates to automated wire insertionsystems for manufacturing processes, such as aircraft or electronicsmanufacturing. More specifically, the present disclosure generallyrelates to a system and method for the insertion of a wire into afixture using vibratory motion.

Description of the Related Art

Typical wire insertion automation machines require very tight tolerancesbetween the expected (programmed) grommet cavity location and the actualposition when mounted to the pallet. Currently, connectors are attachedto the pallet by a rigid threaded fixture that aligns the connector byits outer shell or with a connector friction post. The tolerance stackup of the connector manufacturer, however, may place the connectorcavity locations outside of the tolerance of the programmed positions ofthe automated wire insertion machine, thus causing misalignments and/orhigh failure rates. Automated wire insertion machines have high failurerates due to the collisions between the wire contact and the grommet ordielectric face of the connector. Many of these wire insertion failuresare attributed to the interference fit and high friction of the contactin the compliant grommet material.

As such, there may be a misalignment between the master key on theconnector shell and the grommet cavity holes. Other misalignments mayoccur due to a translational error of the grommet within the shell asthe grommet is glued into the connector by hand. Shifting of the grommetfrequently occurs despite the grommet being self-centered by design.

The tolerance stack up of the connector part induces numerous wireinsertion failures with the use of an automated wire insertion machine.The grommet of many connectors is an interference fit with the wirecontact. Furthermore, the insertion gripper grabs the wire which is lessrigid than the contact. The lack of rigidity in the wire makes fullyseating the wire in the connector difficult. Once a wire contact hasbeen positioned through the grommet, the wire contact must find its wayinto the dielectric cavity, which is rigid. If the wire contact and thedielectric cavity are not perfectly aligned, numerous insertion failuresmay occur. Some current automated wire insertion machines have a certainnumber of programmed retries if the sensor recognizes a failedinsertion. These retries allow the wire contact to back up and try aslightly different position for the next wire insertion. The insertionattempts may form a circular array about the original attempt location.The high friction in the grommet makes it difficult to effectively movethe contact to locate the dielectric hole. Furthermore, multiple failedattempts are time consuming and oftentimes slow production as hundredsor thousands of wires may be required to be inserted in a given system.

Therefore, what is needed in the art is a system and method foreffectively and efficiently inserting a wire into a fixture.

SUMMARY

Examples disclosed herein generally relate to methods and apparatus forthe insertion of one or more wires into a cavity of a fixture of astructure or component. The wire insertion apparatus includes a grommet,a gripper adapted to interface with the grommet, and at least a firstvibrating element. The first vibrating element is connected to andvibrates one or more of the apparatus, the grommet, the gripper, thewire, and/or a component of the apparatus. Vibration, induced in anydirection, enables the cavities to shift position during insertionrelative to the contact, thus increasing the tolerance of the cavity,reducing the failure rate of wire insertion, and reducing totalproduction time. The vibration breaks the static friction of the contactin the grommet or dielectric opening, creates the positive locatingrequired to insert the contact in the grommet and/or dielectric, and/orpivots the contact.

In one example, a wire insertion system is disclosed. The wire insertionsystem includes a fixture, a gripper adapted to interface with thefixture and to support a plurality of wires, and a first vibratingelement. The wire insertion system further includes a sensor and acontroller. The first vibrating element is connected to one or more ofthe fixture or the gripper. The sensor is coupled to the fixture. Thecontroller is coupled to the sensor and in communication with the firstvibrating element and the gripper, and configured to vibrate the firstvibrating element using signals from the sensor.

In another example, a wire insertion system is disclosed. The wireinsertion system includes a fixture, a first vibrating element connectedto the fixture, and a gripper adapted to interface with the fixture andto support a plurality of wires. The wire insertion system furtherincludes a sensor coupled to the fixture, and a controller. The gripperincludes a body, at least one gripping member connected to the gripper,and a second vibrating element connected to the gripper. The controlleris coupled to the sensor and in communication with the first vibratingelement, the second vibrating element, and the gripper, and isconfigured to vibrate the first vibrating element and the secondvibrating element using signals from the sensor.

In another example, a method for inserting a wire into a receptacle isdisclosed. The method includes coupling the wire to a movable grippingdevice, positioning the wire relative to a cavity in the receptacle, andvibrating one or more of the moveable gripping device or the receptacle.The method further includes inserting the wire into the cavity in thereceptacle while vibrating, measuring a change in the vibrating providedto the receptacle versus the vibrating received by the receptacle, andoptimizing the vibrating.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A schematically illustrates a wire insertion system, according toone example.

FIG. 1B schematically illustrates a perspective view of the gripper andreceptacle of the wire insertion system of FIG. 1A, according to oneexample.

FIG. 1C schematically illustrates a cross sectional view of a cavity inthe grommet and dielectric of the wire insertion system of FIGS. 1A and1B, according to one example.

FIG. 2 is a flow chart illustrating operations of a method for insertinga wire into a receptacle, according to one example.

DETAILED DESCRIPTION

Examples disclosed herein generally relate to methods and apparatus forthe insertion of one or more wires into a cavity of a fixture of astructure or component. The wire insertion apparatus includes a grommet,a gripper adapted to interface with the grommet, and at least a firstvibrating element. The first vibrating element is connected to andvibrates one or more of the apparatus, the grommet, the gripper, thewire, and/or a component of the apparatus. Vibration, induced in anydirection, enables the cavities to shift position during insertionrelative to the contact, thus increasing the tolerance of the cavity,reducing the failure rate of wire insertion, and reducing totalproduction time. The vibration breaks the static friction of the contactin the grommet or dielectric opening, creates the positive locatingrequired to insert the contact in the grommet and/or dielectric, and/orpivots the contact.

FIGS. 1A and 1B schematically illustrate a wire insertion system 100 forcoupling a contact 104 of a wire 102 with a grommet 106 and/or adielectric 108 (shown in FIG. 1C). The wire insertion system 100includes a fixture 110. The fixture 110 is a support, base, housing,and/or mount for providing support to system components. In someexamples, the fixture 110 may be a pallet or a connector. In someexamples, the fixture 110 may include a plurality of holes 112 boredtherethrough. The holes 112 may be, for example, screw holes or pinholes for receiving a screw or pin, thus coupling a system component tothe fixture 110. The fixture 110 may comprise a metal material, aplastic material, a rubber material, and/or another suitable material.

The wire insertion system 100 also includes a gripper 114. In someexamples, the gripper 114 is an insertion gripper configured to supporta plurality of wires 102 to insert the plurality of wires 102 into acavity. The gripper 114 is coupled to the fixture 110. The gripper 114includes a body 144 and at least one gripper member 116. In someexamples, the gripper 114 further includes a gripper arm 146 forextending the gripping members 116 outward from the body 144 of thegripper 110. The gripper 114 includes at least one gripping member 116for holding, moving, coupling to, and/or inserting the wire 102 (seeFIG. 1B). In some examples, the gripper 114 includes, for example, twogripping members 116 for holding a wire 102 therebetween, thus allowinga wire 102 to be positioned and/or inserted. In some examples, thegripping members 116 pinch the wire 102 in order to secure the wire andenable the gripper to direct the motion of the wire 102. The gripper maycomprise a metal material, a rubber material, a plastic material, or anyother suitable material for wire handling.

The wire insertion system further includes a first vibrating element118. As shown in FIG. 1A, the first vibrating element 118 is coupled tothe fixture 110. In some examples, however, the first vibrating element118 is connected to one or more of the fixture 110, the gripper 114,grommet 106, and/or the dielectric 108 cavity. In some examples thefirst vibrating element 118 is an eccentric vibrating motor. In someexamples the first vibrating element 118 is a piezoelectric device. Incertain examples, the first vibrating element 118 is coupled to thefixture 110 via a connection mechanism, such as a nut and boltconnection or a screw connection. In other examples, the first vibratingelement 118 is coupled to the gripper 114 via a connection mechanism,such as a nut and bolt connection or a screw connection. The firstvibrating element 118 provides vibratory motion. In some examples, thefirst vibrating element 118 provides vibratory motion within the planeof the direction of insertion. In some examples, the first vibratingelement 118 provides vibratory motion in the plane orthogonal to thedirection of wire insertion, thus enabling the cavities for wireinsertion to effectively shift position during insertion. In otherexamples, the first vibrating element 118 provides vibratory motionparallel to the direction of insertion of the wire, and/or providesvibratory motion in a random direction. It is contemplated, however,that vibratory motion may be provided in any direction and/orcombination of directions. As utilized through this disclosure,vibratory motion includes vibrating and vice versa. Vibrating includesmoving or causing movement continuously.

The wire insertion system 100 further includes a sensor 120. The sensor120 is coupled to the fixture 110. In some examples, the sensor 120 isan accelerometer. In some examples, the sensor 120 may be coupled to thefixture 110 to optimize the vibratory motion. For example, as wirescontinue to be added to system via insertion into a respective grommet106 and/or dielectric 108, each added wire increases the overall weightof the system. The added weight causes the relative vibratory motionprovided by the first vibrating element 118 to increase or decrease. Assuch, the sensor 120 may signal the first vibrating element 118 toincrease or decrease vibration due to the amount of wire added to and/orremoved from the grommet 106 and/or dielectric 108. A feedback loop maybe provided between the sensor 120 and the first vibrating element 118to optimize the vibratory motion and/or to optimize the vibrationamplitude produced by the first vibrating element 118. Therefore, aswires continue to be added and/or removed, the sensor 120 can providefeedback to the first vibrating element 118 such that vibration producedtherefrom is adjusted and/or optimized for subsequent wires to beinserted more easily. In one example, vibration is optimized by alteringand/or adjusting the speed of the first vibrating element 118 and/ordetermining the direction of vibration which creates a greateramplitude, prior to changing the speed or direction of the firstvibrating element 118. In some examples, a local maxima may bedetermined in order to optimize the vibration.

By way of example only, optimizing the vibratory motion may includemeasuring a change in the natural frequency as wires continue to beadded. As such, the sensor 120 may measure the change in the naturalfrequency, thus allowing new wires to continuously be insertedthereafter, due to the change in vibration.

Additionally, in some examples, the sensor may measure a force withwhich a wire 102 is inserted into a respective grommet 106 and/ordielectric 108. If the force with which the wire 102 is inserted is toostrong that the force may damage the wire 102, the contact 104, and/orthe grommet 106 or dielectric 108. As such, the sensor may signal thegripper 114 to stop the insertion process and/or to retry the insertionprocess.

The wire insertion system 100 is controlled by a processor based system,such as a controller 122. The controller 122 includes a programmablecentral processing unit (CPU) 124 that is operable with a memory 126 anda mass storage device 128, an input control unit 130, and a graphicaluser interface (e.g., a display unit) (not shown), and includes powersupplies, clocks, cache, input/output (I/O) circuits, and the like,coupled to the various components of the wire insertion system 100 tofacilitate control of the ongoing wire insertion processes. Thecontroller 122 also includes hardware for monitoring, measuring, andoptimizing vibratory motion and/or the natural frequency of the wireinsertion system 100 and/or its components.

To facilitate control of the wire insertion system 100 described above,the CPU 124 may be one of any form of general purpose computer processorthat can be used in an industrial setting, such as a programmable logiccontroller (PLC), for controlling various sub-processors. The memory 126is coupled to the CPU 124. The memory 126 is non-transitory and may beone or more of readily available memory such as random access memory(RAM), read only memory (ROM), floppy disk drive, hard disk, or anyother form of digital storage, local or remote. Support circuits 132 arecoupled to the CPU 124 for supporting the processor in a conventionalmanner. Measuring vibration, optimizing vibratory motion, and otherprocesses are generally stored in the memory 126, typically as asoftware routine. The software routine may also be stored and/orexecuted by a second CPU (not shown) that is remotely located from thehardware being controlled by the CPU 124.

The memory 126 is in the form of a non-transitory computer-readablestorage media that contains instructions, that when executed by the CPU124, facilitates the operation of the wire insertion system 100. Theinstructions in the memory 126 are in the form of a program product suchas a program that implements the method of the present disclosure. Theprogram code may conform to any one of a number of different programminglanguages. In one example, the disclosure may be implemented as aprogram product stored on computer-readable storage media for use with acomputer system. The program(s) of the program product define functionsof the examples (including the methods described herein). Illustrativecomputer-readable storage media include, but are not limited to: (i)non-writable storage media (e.g., read-only memory devices within acomputer such as CD-ROM disks readable by a CD-ROM drive, flash memory,ROM chips, or any type of solid-state non-volatile semiconductor memory)on which information is permanently stored; and (ii) writable storagemedia (e.g., floppy disks within a diskette drive or hard-disk drive orany type of solid-state random-access semiconductor memory) on whichalterable information is stored. Such computer-readable storage media,when carrying computer-readable instructions that direct the functionsof the methods described herein, are examples of the present disclosure.

The controller 122 stores logic for controlling the first vibratingelement 118, the gripper 114, and/or the sensor 120. The controller 122is coupled to the sensor 120 and in communication with the firstvibrating element 118 and/or the gripper 114. Furthermore, thecontroller 122 is configured to vibrate the first vibrating element 118using signals from the sensor 120. Communication includes a wired and/orwireless connection. A wireless connection includes a connection via,for example, Bluetooth, near field communication (NFC) signal, radiofrequency (RF) signal, Wi-Fi connection, and/or mobile personal areanetwork, among others.

The controller 122 is configured to receive data from the firstvibrating element 118, the fixture 110, and/or the wire insertion system100. The controller 122 calculations a change in the vibrating providedto the wire insertion system 100, the fixture 110, and/or the gripper114 and controls the first vibrating element 118 by adjusting and/oroptimizing the vibrating motion therefrom to conform to the calculatedoptimized vibration and/or vibratory amplitude of the receptacle. Insome examples, the controller 122 calculates a change in a naturalfrequency of the wire insertion system 100, the fixture 110, and/or thegripper 114 and controls the first vibrating element 118 by adjustingthe vibrating motion therefrom to conform to the calculated naturalfrequency of the receptacle.

For example, the controller 122 may be configured to control functioningof each of the fixture 110, the gripper 114, the sensor 120, and/or thewire insertion system 100 during different operations of the wireinsertion process. In some examples, the controller 122 comprises logicand/or is programmed to align a plurality of wires 102 held by thegripper 114 with respective cavities 140 in the grommet 106.

FIG. 1B schematically illustrates a perspective view of a receptacle 134and a gripper 114 of the wire insertion system 100 of FIG. 1A. Thefixture 110 is configured to support the receptacle 134. In someexamples, the receptacle 134 is coupled to the fixture 110. In otherexamples, the receptacle 134 is coupled to a second fixture 136, asshown in FIG. 1B. The receptacle 134 includes a grommet 106 forreceiving a plurality of wires 102 therein. The grommet 106 comprises aplastic material, an elastomeric material, a polymer material, a rubbermaterial, and/or any other suitable material. The grommet 106 includes aplurality of cavities 140 disposed therein. Each cavity 140 isconfigured to receive and/or accept at least one wire 102. Thereceptacle 134 also includes a dielectric 108, as discussed infra withrespect to FIG. 1C. The dielectric 108 is disposed behind the grommet106, such that a wire 102 inserted into the grommet 106 must passthrough the grommet 106 before reaching the dielectric 108. As such, thedielectric 108 receives and/or accepts the contact 104 of the wire.

In some examples, and as shown in FIG. 1B, the wire insertion system 100may further include an optional second vibrating element 142. The secondvibrating element 142 may be substantially similar to the firstvibrating element 118, described supra. Although two vibrating elementsare shown, it is contemplated that only one vibrating element, such asthe first vibrating element 118, may be utilized. It is furthercontemplated, however, that any number of vibrating elements may beutilized. In some examples, the fixture 110 and the gripper 114 are eachcoupled to either the first vibrating element 118 and/or the secondvibrating element 142. The controller 122, in addition to the abovedescribed connections and communications, is also in communication withthe second vibrating element 142. Furthermore, the control 122 is alsoconfigured to vibrate the second vibrating element 142 using signalsfrom the sensor 120. In some examples, the second vibrating element 142is an eccentric vibrating motor. In some examples, the second vibratingelement 142 is a piezoelectric device.

In certain examples, the second vibrating element 142 is coupled to thefixture 110 via a connection mechanism, such as a nut and boltconnection or a screw connection. In other examples, the secondvibrating element 142 is coupled to the gripper 114 via a connectionmechanism, such as a nut and bolt connection or a screw connection. Inother examples, the second vibrating element 142 is coupled to thefixture 110 while the first vibrating element 118 is coupled to thegripper, or vice versa. The second vibrating element 142 providesvibratory motion. In some examples, the second vibrating element 142provides vibratory motion within a plane of the direction of insertion.In some examples, the second vibrating element 142 provides vibratorymotion in a plane orthogonal to the direction of wire insertion, thusenabling the cavities for wire insertion to effectively shift positionduring insertion. In other examples, the second vibrating element 142provides vibratory motion parallel to the direction of insertion of thewire, provides vibratory motion in a random direction, and/orcombinations thereof.

It is contemplated that the wire insertion system 100 shown in FIG. 1Aand the receptacle 134 shown in FIG. 1B may be operatively connected insome examples, while in other examples the wire insertion system 100 andthe receptacle are separate and distinct systems. In such an example,the wire insertion system 100 may be moveable and/or portable such thatthe wire insertion system 100 may be utilized with any receptacle at anylocation.

FIG. 1C schematically illustrates a cross-sectional view of a cavity 140of the grommet 106 and dielectric 108 of the wire insertion system 100of FIGS. 1A and 1B, according to one example. As shown, the cavity 140through the grommet 106 and into the dielectric 108 are not aligned andan offset exists been the grommet 106 and the dielectric 108. Thisoffset may be due to the manufacturing process and tolerance of theconnectors. As shown, the gripper 114 grips a region of the wire 102allowing the contact 104 to remain free. The region between where thegripper 114 grabs the wire 102 and the area where the contact 104 iscrimped to the wire allows for movement of the contact during theinsertion process. This area is shown as the compliant region 138 inFIG. 1C.

The wire 102 and the contact 104 together make up a wire assembly. Assuch, upon insertion of the wire assembly into the grommet 106 and/ordielectric 108, the wire assembly may fail to properly insert correctlyinto the dielectric 108. Vibrations from the first vibrating member 118,and in some examples the optional second vibrating member 142, assistwith the wire assembly insertion into the grommet 106 and/or dielectric108. Through the use of vibration, the static friction between the wireassembly, the grommet 106, and/or the dielectric is broken, thuspermitting the wire assembly to pass through the grommet 106 with agreater degree of success and allow the contact 104 to be properlyseated in the dielectric 108. Once the contact 104 has passed throughthe grommet 106, the vibration further aids the contact 104 in locatingthe centroid of the dielectric cavity.

FIG. 2 schematically illustrates operations of a method for inserting awire in a receptacle. In some embodiments, the receptacle includes afixture, a base, a housing, a grommet, and/or a dielectric. At operation210, a wire is coupled to a moveable gripping device. The moveablegripping device receives a wire by gripping the wire with one or moregripping members. The moveable gripping device grips the wire, withoutgripping the contact. As such, the moveable gripping device ispositioned between about 0.01 inches and about 20 inches from thecontact. In some examples, the gripper may grip the wire as close to thecontact as possible without gripping the contact. By way of exampleonly, in some examples, the grip of the gripper is maintained such thatthe gripper is continuously about 0.2 inches from the outer face of thegrommet. It is contemplated, however, that in some examples the gripperand/or the gripping member may grip the contact of the wire.

At operation 220, the wire is positioned relative to a cavity in thereceptacle. As such, the cavity is located and the wire is positioned.In some examples, the moveable gripping device moves and/or extends thewire towards a cavity in the grommet of the receptacle, such that thecontact is positioned to be received by the receptacle.

At operation 230, one or more of the moveable gripping device, the wire,the grommet, the dielectric, and/or the receptacle is vibrated. In someexamples, only the receptacle is vibrated, while in other examples onlythe gripper is vibrated, while in other examples the entire fixture isvibrated. Furthermore, in some examples, the grommet and/or dielectricmay also be vibrated individually or along with other system components,discussed supra. Additionally, in some examples, the wire is vibrateddirectly. The vibration is one or more of vibrating in a motionperpendicular to the direction of insertion of the wire, vibrating in amotion orthogonal to the direction of insertion of the wire, vibratingin a motion parallel to the direction of insertion of the wire,vibrating in a circular direction relative to the longitudinal axis ofthe wire, and/or vibrating in a random motion. It is furthercontemplated, however, that in some examples the contact may be vibrateddirectly.

At operation 240, the wire is inserted into the cavity in the receptaclewhile vibrating. The vibrating may be occurring in any one or more ofthe moveable gripping device, the wire, the grommet, the dielectric, thecavity, and/or the receptacle, as described supra. The insertingincludes holding the wire at a first location with the movable grippingdevice and connecting the wire with the cavity. Connecting the wire withthe cavity includes inserting the wire via the moveable gripping deviceinto the cavity. Once the wire is partially inserted into the cavity,the moveable gripping device releases the wire from the first locationand moves away from the contact of the wire. As such, the insertingfurther includes gripping the wire at a second location, wherein thesecond location is a greater distance from the contact than the firstlocation. The inserting further includes connecting the wire with thecavity such that the wire is frictionally coupled to the cavity.

At operation 250, a change in the vibration provided to the receptacleis measured versus the vibration received by the receptacle. In someexamples, an accelerometer operatively connected to the receptacle isutilized to measure the change in the vibration as wires are insertedinto the receptacle. In some examples, the vibration of the entire itembeing vibrated is measured and compared against a prior vibrationprovided before insertion of the wire. The difference between thevibrations measured results in the net change in the vibration. In someexamples, the controller stores logic for determining and measuring thevibration.

By way of example only, measuring the change in the vibration mayinclude measuring a change in the natural frequency of the receptacle.In some examples, the accelerometer, which is operatively connected tothe receptacle, is utilized to measure the change in the naturalfrequency as wires are inserted into the receptacle. The naturalfrequency of the entire item being vibrated is measured and compared toa previously measured natural frequency prior to the insertion of thewire. The difference between the natural frequencies measures results inthe change in the natural frequency. In some examples, the controllerstores logic for determining and measuring the natural frequency.

At operation 260, vibration is optimized. As additional wires arecoupled to the receptacle, additional weight is added to the receptacle.The additional weight may change the effect of and/or the strength ofthe vibration received by the receptacle thereby changing the vibrationrequired to easily insert proximate wires. The change in the vibrationrequired may increase the vibration or decrease the relative strength ofthe vibration provided. As such, the vibration is calibrated, optimized,and/or adjusted such that the wires may be easily inserted therein. Bycontinuously optimizing the vibration, any number of wires may beinserted into a receptacle of any desirable size without regard to theweight of the wires. It is contemplated that optimizing the vibrationmay include optimizing the vibration amplitude. As discussed supra, inone example, vibration is optimized by altering the first and/or secondvibratory element to produce higher or lower vibrations and/ordetermining which vibratory directions create the greatest amplitude.Furthermore, a local maxima may be located.

By way of example only, optimizing the vibration may include adjustingthe vibration to approximately the natural frequency of the receptacle.As additional wires are coupled to the receptacle, additional weight isadded to the receptacle. The additional weight may change the naturalfrequency of the receptacle thereby changing the vibration required. Thechange in the vibration required may increase the vibration or decreasethe vibration. As such, the vibration is calibrated to the naturalfrequency of the receptacle and/or the entire system being vibrated. Bycontinuously optimizing the natural frequency, any number of wires maybe inserted in to a receptacle of any desirable size without regard tothe weight of the wires.

The method 200 further includes repeating operations 210-260 until allwires of the system have been inserted.

Testing was completed using an eccentric rotating motor affixed to afixture for on-machine testing. The vibration of the fixture wasmeasured with a vibration measuring device. An insertion test wasperformed first without vibration as a control. The test was thenrepeated and completed with the vibrating element mounted to the fixtureand insertion successes and failures were recorded. Results indicatedthat the vibrating trial maintained fewer wire insertion failures ascompared to the non-vibrating test results. In fact, the vibrating trialindicated zero failed insertion attempts while the non-vibrating trialindicated an average of two or more failed attempts.

Further test results indicated that the force required to insert a wireinto the receptacle including the grommet and dielectric was loweredwith the use of vibration. As such, vibration increases the relativediameter of the cavity as seen by the contact and wire.

The subject matter described herein provides a vibrating mechanism thatvibrates a wire insertion system or component thereof to enable cavitiesin a grommet and/or dielectric to effectively shift position during wireinsertion relative to the contact of the wire. As such, wire insertionfailure rates are reduced due to a number of factors. First, failurerates are reduced as constant vibration breaks static friction of thecontact of the wire in the grommet or dielectric cavity. Static frictionis highest when there is an insertion failure, and the manufacturingprocess pauses to retry in a slightly offset cavity position.Additionally, failure rates are reduced as vibration creates thepositive locating required to insert the tip of the contact into thegrommet cavity prior to inserting the wire fully into the grommetcavity. Furthermore, failure rates are reduced as vibration creates thepositive locating necessary to insert the tip of the contact into thegrommet cavity prior to inserting the wire fully into the dielectriccavity. Vibration helps to pivot the contact during the insertionprocess to properly and accurately seat the contact within thedielectric, therefore minimizing the use of the system retry feature.The flexible wire is held by the insertion gripper, while the contact isfree to pivot about the edge of the grommet.

Furthermore, the subject matter described herein provides for a saferand automated work environment, a decrease in the number of toolsrequired, a reduction in potential for foreign object damage to the wireand/or receptacle, thus reducing costs and improving safety, and areduction in the probability of damage to components and surroundings.

It should be noted, while reference is made throughout the disclosure toa fixture or receptacle for wire insertion using vibration, it iscontemplated that the present disclosure may be utilized for vibratorywire insertion or other mechanical and electrical needs with respect tovarious structures, components, parts, and system.

The descriptions of the various examples of the present invention havebeen presented for purposes of illustration, but are not intended to beexhaustive or limited to the examples disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the described examples.The terminology used herein was chosen to best explain the principles ofthe examples, the practical application or technical improvement overtechnologies found in the marketplace, or to enable others of ordinaryskill in the art to understand the examples disclosed herein.

In the following, reference is made to examples presented in thisdisclosure. However, the scope of the present disclosure is not limitedto specific described examples. Instead, any combination of thefollowing features and elements, whether related to different examplesor not, is contemplated to implement and practice contemplated examples.Furthermore, although examples disclosed herein may achieve advantagesover other possible solutions or over the prior art, whether or not aparticular advantage is achieved by a given example is not limiting ofthe scope of the present disclosure. Thus, the following aspects,features, examples and advantages are merely illustrative and are notconsidered elements or limitations of the appended claims except whereexplicitly recited in a claim(s). Likewise, reference to “the invention”shall not be construed as a generalization of any inventive subjectmatter disclosed herein and shall not be considered to be an element orlimitation of the appended claims except where explicitly recited in aclaim(s).

While the foregoing is directed to examples of the present invention,other and further examples of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

What is claimed is:
 1. A wire insertion system, comprising: a fixture; agripper configured to interface with the fixture and to support a wire;a first vibrating element connected to one or more of the fixture andthe gripper; a sensor coupled to the fixture; and a controller coupledto the sensor and in communication with the first vibrating element andthe gripper, and configured to vibrate the first vibrating element usingsignals from the sensor.
 2. The wire insertion system of claim 1,wherein the first vibrating element is an eccentric vibrating motor. 3.The wire insertion system of claim 1, wherein the first vibratingelement is a piezoelectric device.
 4. The wire insertion system of claim1, wherein the wire comprises a plurality of wires.
 5. The wireinsertion system of claim 4, wherein the fixture is configured tosupport a grommet having a plurality of cavities with each cavityconfigured to accept a respective wire of the plurality of wires.
 6. Thewire insertion system of claim 5, wherein the controller is programmedto align each of the plurality of wires held in the gripper with therespective cavity in the grommet.
 7. The wire insertion system of claim1, further comprising a second vibrating element, and wherein thefixture is connected to the first vibrating element and the gripper isconnected to the second vibrating element.
 8. The wire insertion systemof claim 7, wherein the controller is in operable communication with thesecond vibrating element.
 9. The wire insertion system of claim 1,wherein the sensor is an accelerometer.
 10. The wire insertion system ofclaim 1, wherein the first vibrating element is connected to thefixture.
 11. The wire insertion system of claim 1, wherein the firstvibrating element is connected to the gripper.
 12. The wire insertionsystem of claim 1, wherein the gripper is configured to movably supportthe wire with respect to the fixture.
 13. The wire insertion system ofclaim 1, wherein the first vibrating element is configured to vibratethe one or more of the fixture and the gripper when the gripper supportsthe wire.
 14. A wire insertion system, comprising: a fixture; a gripperconfigured to interface with the fixture and to movably support a wirewith respect to the fixture; and a first vibrating element connected toone or more of the fixture and the gripper and configured to vibrate theone or more of the fixture and the gripper when the gripper supports thewire.
 15. A method for inserting a wire into a receptacle, comprising:(a) coupling a wire to a moveable gripping device; (b) positioning thewire relative to a cavity in the receptacle; (c) vibrating one or moreof the moveable gripping device, the wire, or the receptacle; (d)inserting the wire into the cavity in the receptacle while vibrating;(e) measuring a change in the vibrating provided to the receptacleversus the vibrating received by the receptacle; and (f) optimizing thevibrating.
 16. The method of claim 15, further comprising repeating(a)-(f) until all wires have been inserted.
 17. The method of claim 15,wherein the inserting comprises: holding the wire at a first locationwith the moveable gripping device; connecting the wire with the cavity;holding the wire at a second location with the moveable gripping device,wherein the second location is located a greater distance from thecavity than the first location; and connecting the wire with the cavity.18. The method of claim 15, wherein the vibrating is in one or more ofmotion perpendicular to the direction of insertion of the wire,orthogonal to the direction of insertion of the wire, parallel to thedirection of insertion of the wire, random vibration, or anycombinations thereof.
 19. The method of claim 18, wherein the vibratingis only orthogonal to the direction of insertion of the wire.
 20. Themethod of claim 15, wherein the vibrating comprises vibrating themoveable gripping device and the receptacle.